System, method and apparatus for fiber bonding procedure for optoelectronic packaging

Abstract

A method and apparatus for bonding optical fibers are disclosed. A fiber bonding device feeds an optical fiber through a supportive sheath having a ceramic tip at its end. The optical fiber extends slightly beyond the ceramic tip and is aligned with the focal point of a laser, which causes the end of the optical fiber to melt, forming a molten region. The ceramic tip then extends partially into a substrate surface, causing the molten region of the optical fiber to become bonded to the substrate. The process is controlled by computer logic, such that it is an automated, precision process for bonding optical fibers.

1. An optical fiber bonded to a substrate, comprising:
 an optical fiber having an end region; and  
 said end region of the optical fiber having a functional junction with a substrate, wherein the functional junction is formed solely between the end region of the optical fiber and the substrate surface,  
 wherein said optical fiber is advanced or retracted by a fiber feeding unit, and  
 wherein a multi-directional stage mounted beneath said fiber feeding unit moves in a plurality of directions positioning said optical fiber in relation to said substrate.  
 
   
   
     2. The optical fiber of  claim 1  wherein the substrate is a semiconductor. 
   
   
     3. The optical fiber of  claim 1  wherein the substrate is a vertical cavity surface emitting laser. 
   
   
     4. The method of  claim 1  wherein the substrate is a functional component not limited to light transmission. 
   
   
     5. The method of  claim 1  wherein the substrate comprises a material selected from a group consisting of silicon, fused silica and silicate glass. 
   
   
     6. An optical fiber bonded to a substrate, comprising:
 an optical fiber having an end region; and  
 said end region being bonded directly to a substrate without a coupling component;  
 wherein the optical fiber is advanced or retracted by a fiber feeding unit, and  
 wherein a multi-directional stage mounted beneath said fiber feeding unit moves in a plurality of directions positioning said optical fiber in relation to said substrate.  
 
   
   
     7. A method for bonding an optical fiber to a substrate, the method comprising:
 providing a laser beam having a focal point;  
 aligning a substrate adjacent the laser beam focal point;  
 extending an optical fiber along a support structure having an alignment tip;  
 extending one end of the optical fiber beyond the alignment tip of the support structure, into the laser beam focal point;  
 after the end of the optical fiber melts in the laser beam focal point, extending the melted end of the optical fiber together with the alignment tip of the support structure into the surface of the substrate;  
 moving at least one of the multi-directional stage and the support structure for aligning the focal point of a laser to said one end of the optical fiber; and  
 retracting the alignment tip of the support structure such that the end of the optical fiber retains direct contact with the substrate.  
 
   
   
     8. The method of  claim 7  further comprising hearing the substrate surface before the step of extending the melted end of the optical fiber together with the alignment tip of the support structure into the surface of the substrate. 
   
   
     9. The method of  claim 7  wherein the support structure comprises a tubular support member; wherein
 the extending an optical fiber along a support structure comprises extending the optical fiber through the tubular support member; and wherein  
 the alignment tip comprises a ceramic material.  
 
   
   
     10. The method of  claim 7  wherein the providing a laser beam having a focal point comprises:
 converting a continuous wave of the laser beam to pulses.  
 
   
   
     11. The method of  claim 7  wherein the focal point comprises a spot having a diameter approximately between 20 μm and 30 μm. 
   
   
     12. The method of  claim 7  wherein the extending one end of the optical fiber beyond the alignment tip, into the laser beam focal point, is controlled by a digital output of a computer processor. 
   
   
     13. A fiber bonding device using a laser light source and at least one lens for creating a focal point to heat an end of an optical fiber comprising;
 a fiber feeding unit for routing an optical fiber;  
 a solenoid connected to the fiber feeding unit and having an opening for an optical fiber to pass through; and  
 a hollow support member having a first end and a second end, the first end operatively connected to the solenoid and the second end having an alignment tip connected thereto; and  
 the solenoid operable for feeding the optical fiber through the hollow support member.  
 
   
   
     14. A fiber bonding device utilizing focused laser light for heating an optical fiber comprising:
 a fiber feeding unit for routing an optical fiber;  
 a first solenoid connected to the fiber feeding unit and having an opening for an optical fiber to pass through;  
 a hollow support member having a first end and a second end, the first end operatively connected to the solenoid and the second end having an alignment tip connected thereto;  
 the first solenoid operable for feeding the optical fiber through the hollow support member;  
 a motor, attached to the fiber feeding unit; and  
 a second solenoid, operatively connected to the motor, for routing a fiber through the fiber feeding unit.  
 
   
   
     15. The fiber bonding device of  claim 14  wherein the alignment tip comprises a ceramic material. 
   
   
     16. The fiber bonding device of  claim 14  wherein the hollow support member comprises a tubular structure capable of having an optical fiber passed therethrough. 
   
   
     17. A fiber bonding device comprising:
 a laser generating device having a laser beam that passes through a focusing lens;  
 a fiber feeding unit for routing an optical fiber;  
 a solenoid connected to the fiber feeding unit and having an opening for an optical fiber to pass through;  
 a hollow support member having a first end and a second end, the first end operatively connected to the solenoid and the second end having an alignment tip connected thereto;  
 the solenoid operable for feeding the optical fiber through the hollow support member;  
 a multi-directional stage mounted beneath the fiber feeding unit;  
 the focusing lens, mounted on the multi-directional stage; and  
 the multi-directional stage, and the fiber feeding unit and focusing lens mounted thereon, movable in a plurality of directions.  
 
   
   
     18. An apparatus for bonding an optical fiber to a substrate, the apparatus comprising:
 a laser generating device for generating a laser beam;  
 a mirror for directing the laser beam through a modulator for converting the laser beam from a continuous wave to a pulse train;  
 a focusing lens for focusing the converted laser beam into a focal point; and  
 a fiber bonding device mounted on a multi-directional stage movable in a plurality of directions for directing an end of an optical fiber into the focal point such that the end of the optical fiber melts and for causing the melted end of the optical fiber to extend toward and bond to the surface of a substrate.  
 
   
   
     19. An apparatus for bonding an optical fiber to a substrate, the apparatus comprising:
 a laser generating device for generating a laser beam;  
 a first mirror for passing a first portion of the laser beam therethrough and reflecting a second portion of the laser beam;  
 an energy sink for collecting the first portion of the laser beam;  
 a second mirror for directing die second portion of the laser beam through a modulator for converting the second portion of the laser beam from a continuous wave to a pulse train;  
 a focusing lens for focusing the converted second portion of the laser beam into a focal point; mid  
 a fiber bonding device mounted on a multi-directional stage movable in a plurality of directions for directing an end of an optical fiber into the focal point such that the end of the optical fiber melts and for causing the melted end of the optical fiber to extend toward and bond to the surface of a substrate.  
 
   
   
     20. The apparatus of  claim 19  further comprising a third mirror for directing the converted second portion of the laser beam through the focusing lens. 
   
   
     21. The apparatus of  claim 19  further comprising:
 a third mirror for reflecting the converted second portion of the laser beam; and  
 a fourth mirror for directing the reflected, converted second portion of the laser beam through the focusing lens.  
 
   
   
     22. The apparatus of  claim 19  wherein the first portion of the laser beam comprises approximately 30% of the laser beam. 
   
   
     23. The apparatus of  claim 19  wherein the laser beam generating device is a CO 2  laser. 
   
   
     24. The apparatus of  claim 19  wherein the laser beam comprises a continuous wave. 
   
   
     25. The apparatus of  claim 19  wherein the modulator converts the laser beam from a continuous wave to a pulse wave.